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Ultrasonic Machining

By Rakesh Chander Saini rcsaini.blogspot.com

Ultrasonic Machining (USM)


Content Introduction History Principle of Ultrasonic Machining Mechanism Materials that can be USMed Applications Limitations Advantages Disadvantages
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Introduction
Ultrasonic- A vibratory wave having larger than upper frequency limit of human ear(usually greater that 16 kc/s). In USM, material is removed by the abrasive grains which are driven into the work surface by a tool oscillating normal to the work surface. To understand the working principle of USM, consider that a particle p is thrown on the wax wall with a certain force F1. It will penetrate the wall to a length l1. If the same particle thrown with force f2 and f3(f3>f2>f1) that will penetrate rcsaini.blogspot.com the wall (l3>l2>l1). USM works

History
The roots of ultrasonic technology can be traced back to research on the piezoelectric effect conducted by Pierre Curie around 1880. He found that asymmetrical crystals such as quartz and Rochelle salt (potassium sodium titrate) generate an electric charge when mechanical pressure is applied. Conversely, mechanical vibrations are obtained by applying electrical oscillations to the same crystals. One of the first applications for Ultrasonic was sonar (an acronym for sound navigation ranging). It was employed on a large scale by the U.S. Navy during World War II to detect enemy submarines. Frequency values of up to 1Ghz (1 billion cycles per second) have been used in the ultrasonic industry. Today's Ultrasonic applications include medical imaging (scanning the unborn fetus) and testing for cracks in airplane construction.rcsaini.blogspot.com

In the process of Ultrasonic Machining, material is removed by micro-chipping or erosion with abrasive particles. In USM process, the tool, made of softer material than that of the workpiece, is oscillated by the Booster and Sonotrode at a frequency of about 20 kHz with an amplitude of about 25.4 um (0.001 in). The tool forces the abrasive grits, in the gap between the tool and the workpiece, to impact normally and successively on the work rcsaini.blogspot.com surface, thereby machining

Principle of Ultrasonic Machining

Principle of Ultrasonic Machining During one strike, the tool


moves down from its most upper remote position with a starting speed at zero, then it speeds up to finally reach the maximum speed at the mean position. Then the tool slows down its speed and eventually reaches zero again at the lowest position. When the grit size is close to the mean position, the tool hits the grit with its full speed. The smaller the grit size, the lesser the momentum it receives from the tool. Therefore, there is an effective speed zone for the rcsaini.blogspot.com tool and, correspondingly

Principle of Ultrasonic Machining In the machining process, the tool, at some point, impacts on
the largest grits, which are forced into the tool and workpiece. As the tool continues to move downwards, the force acting on these grits increases rapidly, therefore some of the grits may be fractured. As the tool moves further down, more grits with smaller sizes come in contact with the tool, the force acting on each grit becomes less. Eventually, the tool comes to the end of its strike, the number of grits under impact force from both the tool and the workpiece becomes maximum. Grits with size larger than the minimum gap will penetrate into the tool and work surface to different extents according to their diameters rcsaini.blogspot.com and the hardness of both surfaces.

USM System
Power supply Transducer Tool Holder Tool Abrasives

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USM System
Power supply
o High power sine wave generator converts low frequency (60Hz) electrical power to high frequency (20KHZ) electrical power.

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USM System
Transducer-convert electrical energy into mechanical
vibration

o Piezoelectric Transducers

Piezoelectric transducers employ the inverse piezoelectric effect using natural or synthetic single crystals (such as quartz) or ceramics (such as barium titanate) which have strong piezoelectric behavior. Ceramics have the advantage over crystals in that they are easier to shape by casting, pressing and extruding.

The charge is directionally proportional to the applied voltage. To obtain high amplitude vibrations the length of the crystal must be matched to the frequency of the generator which produces resonant conditions.
Available up to 900W power capacity.
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USM System
o Magnetostrictive transducers
Working on Longitudinal Magnetostriction* principle Magnetostrictive transducers use the inverse magnetostrictive effect to convert magnetic energy into ultrasonic energy. This is accomplished by applying a strong alternating magnetic field to certain metals, alloys and ferrites. The transducer has solenoid type winding of wire over a stack of nickel laminations (which has rapid dimensional change when placed in magnetic fields)rcsaini.blogspot.com and is fed with an A.C supply

USM System
Tool Holder
o The shape of the tool holder is cylindrical or conical, or a modified cone which helps in magnifying the tool tip vibrations. o In order to reduce the fatigue failures, it should be free from nicks, scratches and tool marks and polished smooth.

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USM System
Tool
o Tool material should be tough and ductile. Low carbon steels and stainless steels give good performance. o Tools are usually 25 mm long ; its size is equal to the hole size minus twice the size of abrasives. o Mass of tool should be minimum possible so that it does not absorb the ultrasonic energy.
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USM System
Abrasive Slurry
o The abrasive slurry contains fine abrasive grains. The grains are usually boron carbide, aluminum oxide, or silicon carbide ranging in grain size from 100 for roughing to 1000 for finishing. o It is used to microchip or erode the work piece surface and it is also used to carry debris away from the cutting area.
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Applications
It is mainly used for (1) drilling (2) grinding, (3) Profiling (4) coining (5) piercing of dies (6) welding operations on all materials which can be treated suitably by abrasives.
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Limitations
Under ideal conditions, penetration rates of 5 mm/min can be obtained. Power units are usually 500-1000 W output. Specific material removal rate on brittle materials is 0.018 mm/Joule. Normal hole tolerances are 7-25m and a surface finish of 0.25 to 0.75m. Works Satisfactory when workpiece hardness is greater than HRC40. Aspect ratio(depth to dia.) 40:1
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Advantages of USM
Machining any materials regardless of their conductivity USM apply to machining semi-conductor such as silicon, germanium etc. USM is suitable to precise machining brittle material. USM does not produce electric, thermal, chemical abnormal surface. Can drill circular or non-circular holes in very hard materials Less stress because of its non-thermal characteristics
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Disadvantages of USM
USM has low material removal rate. Tool wears fast in USM. Machining area and depth is restraint in USM.

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Thank You
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